Composite by infiltration

Claim 2

A process for producing a composite consisting essentially of from about 30% by volume to about 95% by volume of a continuous matrix phase and from about 5% by volume to about 70% by volume of a ceramic filler phase and having a porosity of less than about 10% by volume which consists essentially of forming a ceramic filler into a compact, said compact having an open porosity ranging from about 30% by volume to about 95% by volume of the compact, contacting said compact with an alkaline earth silicate and/or an alkaline earth aluminosilicate infiltrant selected from the group consisting of barium silicate, barium aluminosilicate, calcium silicate, calcium aluminosilicate, magnesium silicate, magnesium aluminosilicate, strontium silicate, strontium aluminosilicate, and a mixture thereof, heating the resulting structure to an infiltration temperature ranging from the liquidus temperature of said infiltrant to below the temperature at which there is significant vaporization of said infiltrant, infiltrating the resulting infiltrant into said compact to produce an infiltrated compact having the composition of said composite, and cooling said infiltrated compact producing said composite, said process being carried out in an atmosphere or vacuum in which there is no significant reaction between said ceramic filler and said infiltrant.

Claim 3

The process according to claim 1 wherein said alkaline earth silicate is represented by the stoichiometric formula xMO.zSiO 2 where M=Ba, Ca, Mg, Sr and a mixture thereof, where x is 1, 2 or 3 and z is 1, 2 or 3, and wherein each oxidic constituent of said stoichiometric formula ranges up to ±50% from its stoichiometric composition.

Claim 4

The process according to claim 1 wherein said alkaline earth aluminosilicate is represented by the stoichiometric formula xM'O.yAl 2 O 3 .zSiO 2 , where M'=Ba, Ca, Mg, Sr and a mixture thereof, where x is 1, 2, 4 or 6, where y is 1, 2, 5 or 9, where z is 1, 2 or 5 and wherein each oxidic constituent of said stoichiometric formula ranges up to±50% from its stoichiometric composition.

Claim 5

The process according to claim 1 wherein said ceramic filler is a ceramic carbide selected from the group consisting of boron carbide, hafnium carbide, niobium carbide, silicon carbide, tantalum carbide, titanium carbide, vanadium carbide, zirconium carbide and a mixture thereof.

Claim 6

The process according to claim 1 wherein said ceramic filler is a ceramic nitride selected from the group consisting of hafnium nitride, niobium nitride, silicon nitride, tantalum nitride, titanium nitride, vanadium nitride, zirconium nitride and a mixture thereof.

Claim 7

The process according to claim 1 wherein said composite is comprised of from about 35% by volume to about 75% by volume of continuous alkaline earth silicate or aluminosilicate phase and about 25% by volume to about 65% by volume of ceramic filler phase and wherein said compact has an open porosity ranging from about 35% by volume to about 75% by volume of said compact.

Claim 8

The process according to claim 1 wherein said ceramic filler is comprised of particles.

Claim 9

The process according to claim 1 wherein said ceramic filler is comprised of filaments.

Claim 10

The process according to claim 1 wherein said ceramic filler is comprised of a mixture of particles and filaments.

Claim 11

The process according to claim 1 wherein said infiltration temperature ranges from about 1300° C. to about 1900° C.

Claim 12

The process according to claim 1 wherein said calcium silicate is CaO.SiO 2 wherein each oxidic constituent of said CaO.SiO 2 ranges up to ±50% from its stoichiometric composition.

Claim 13

The process according to claim 1 wherein said strontium silicate is SrO.SiO 2 wherein each oxidic constituent of said SrO.SiO 2 ranges up to ±50% from its stoichiometric composition.

Claim 14

The process according to claim 1 wherein said strontium aluminosilicate is SrO.Al 2 O 3 . 2SiO 2 wherein each oxidic constituent of said SrO.Al 2 O 3 2SiO 2 ranges up to ±50% from its stoichiometric composition.

Claim 15

A process for producing a composite consisting essentially of from abou 30% by volume to about 95% by volume of a continuous matrix phase and from about 5% by volume to about 70% by volume of a ceramic filler phase and having a porosity of less than about 10% by volume which consists essentially of forming a ceramic filler into a compact, said compact having an open porosity ranging from about 30% by volume to about 95% by volume of the compact, contacting said compact with an alkaline earth silicate and/or an alkaline earth aluminosilicate infiltrant selected from the group consisting of barium silicate, barium aluminosilicate, calcium silicate, calcium aluminosilicate, magnesium silicate, magnesium aluminosilicate, strontium silicate, strontium aluminosilicate, and a mixture thereof, heating and resulting structure to a temperature ranging from about 800° C. to below the melting point of said infiltrant for a time sufficient to degas any desorbable material from said ceramic filler, heating the resulting desorbed structure to an infiltration temperature ranging from the liquidus temperature of said infiltrant to below the temperature at which there is significant vaporization of said infiltrant, infiltrating the resulting liquid infiltrant into said compact to produce an infiltrated compact having the composition of said composite, and cooling said infiltrated compact producing said composite, said process being carried out in an atmosphere or vacuum in which there is no significant reaction between said ceramic filler and said infiltrant.

Claim 16

A process for producing a composite consisting essentially of from abou 30% by volume to about 95% by volume of a continuous matrix phase and from about 5% by volume to about 70% by volume of a ceramic filler phase and having a porosity of less than about 10% by volume which consists essentially of forming a ceramic filler into a compact, said compact having an open porosity ranging from about 30% by volume to about 95% by volume of the compact, contacting said compact with an alkaline earth silicate and/or an alkaline earth aluminosilicate infiltrant selected from the group consisting of barium silicate, barium aluminosilicate, calcium silicate, calcium aluminosilicate, magnesium silicate, magnesium aluminosilicate, strontium silicate, strontium aluminosilicate, and a mixture thereof, heating and resulting structure to a temperature ranging from about 800° C. to below the melting point of said infiltrant for a time sufficient to degas any desorbable material from said ceramic filler, heating the resulting desorbed structure to an infiltration temperature ranging from the liquidus temperature of said infiltrant to below the temperature at which there is significant vaporization of said infiltrant, infiltrating the resulting liquid infiltrant into said compact to produce an infiltrated compact having the composition of said composite, and cooling said infiltrated compact producing said composite, said process being carried out in an atmosphere or vacuum in which there is no significant reaction between said ceramic filler and said infiltrant.

Claim 17

The process according to claim 14 wherein said infiltration temperature ranges from about 1300° C. to about 1900° C.

Claim 18

The process according to claim 14 wherein said infiltrant is CaO.SiO 2 wherein each oxidic constituent of said CaO.SiO 2 ranges up to ±50% from its stoichiometric composition.

Claim 19

The process according to claim 14 wherein said infiltrant is SrO.SiO 2 wherein each oxidic constituent of said Sr.SiO 2 ranges up to ±50% from its stoichiometric composition.

Claim 20

The process according to claim 14 wherein said infiltrant is SrO.Al 2 O 3 .2SiO 2 wherein each oxidic constituent of said SrO.Al 2 O 3 .2SiO 2 ranges up to ±50% from its stoichiometric composition.

Claim 21

A composite having a porosity of less than about 10% by volume consisting essentially of polycrystalline inorganic filler ranging in amount from about 5% by volume to about 70% by volume of said composite, said filler being free of oxide filler, and a continuous interconnecting polycrystalline alkaline earth silicate matrix phase ranging in amount from about 95% by volume to about 30% by volume of said composite, said matrix phase being distributed through said composite, the thickness of said matrix phase between said filler ranging from about 0.1 micron to about 10 microns, said filler being free of oxide filler, said alkaline earth silicate phase being represented by the stoichiometric formula xMO.zSiO 2 where M=Ba, Ca, Mg, Sr and a mixture and/or solid solution thereof, where x is 1, 2 or 3 and z is 1, 2 or 3, and wherein said MO and SiO 2 constituent of said stoichiometric formula ranges less than ±10% from said stoichiometric formula, said composite containing an amorphous glassy phase in an amount of less than about 5% by volume of said composite, said composite containing no significant reaction product of said filler and said matrix phase.

Claim 22

A composite having a porosity of less than about 10% by volume consisting essentially of polycrystalline inorganic filler ranging in amount from about 5% by volume to about 70% by volume of said composite, said filler being free of oxide filler, and a continuous interconnecting polycrystalline alkaline earth silicate matrix phase ranging in amount from about 95% by volume to about 30% by volume of said composite, said matrix phase being distributed through said composite, the thickness of said matrix phase between said filler ranging from about 0.1 micron to about 10 microns, said filler being free of oxide filler, said alkaline earth silicate phase being represented by the stoichiometric formula xMO.zSiO 2 where M=Ba, Ca, Mg, Sr and a mixture and/or solid solution thereof, where x is 1, 2 or 3 and z is 1, 2 or 3, and wherein said MO and SiO 2 constituent of said stoichiometric formula ranges less than ±10% from said stoichiometric formula, said composite containing an amorphous glassy phase in an amount of less than about 5% by volume of said composite, said composite containing no significant reaction product of said filler and said matrix phase.

Claim 23

The composite according to claim 19 wherein said ceramic filler phase is comprised of a ceramic carbide selected from the group consisting of boron carbide, hafnium carbide, niobium carbide, silicon carbide, tantalum carbide, titanium carbide, vanadium carbide, zirconium carbide and a mixture thereof.

Claim 24

The composite according to claim 19 wherein said ceramic filler phase is comprised of a ceramic nitride selected from the group consisting of hafnium nitride, niobium nitride, silicon nitride, tantalum nitride, titanium nitride, vanadium nitride, zirconium nitride and a mixture thereof.

Claim 25

The composite according to claim 19 wherein said ceramic filler phase is comprised of a ceramic boride selected from the group consisting of HfB 2 , NbB, NbB 2 , TaB, TaB 2 , TiB 2 , VB, VB 2 , ZrB 2 and a mixture thereof.

Claim 26

The composite according to claim 19 wherein said composite is comprised of from about 25% by volume to about 65% by volume of said ceramic filler phase, and from about 35% by volume to about 75% by volume of said continuous phase.

Claim 27

The composite according to claim 19 wherein said ceramic filler phase is comprised of particles.

Claim 28

The composite according to claim 19 wherein said ceramic filler phase is comprised of filaments.

Claim 29

The composite according to claim 19 wherein said ceramic filler phase is comprised of a mixture of particles and filaments.

Claim 30

The composite according to claim 19 wherein said infiltrant is CaO.SiO 2 wherein each oxidic constituent of said CaO.SiO 2 ranges up to ±50% from its stoichiometric composition.

Claim 31

The composite according to claim 19 wherein said infiltrant is SrO.SiO 2 wherein each oxidic constituent of said SrO.SiO 2 ranges up to ±50% from its stoichiometric composition.

Claim 32

A composite having a porosity of less than about 5% by volume consisting essentially of polycrystalline inorganic filler ranging in amount from about 5% by volume to about 70% by volume of said composite, said filler being free of oxide and silicon nitride fillers, and a continuous interconnecting polycrystalline alkaline earth aluminosilicate matrix phase ranging in amount from about 95% by volume to about 30% by volume of said composite, said matrix phase being distributed through said composite, the thickness of said matrix phase between said filler ranging from about 0.1 micron to about 10 microns, said alkaline earth aluminosilicate phase being represented by the stoichiometric formula xM'O.yAl 2 O 3 .zSiO 2 where M'=Ca, Mg, Sr and a mixture and/or solid solution thereof, where x is 1, 2, 4 or 6, where y is 1, 2, 5 or 9, where z is 1, 2 or 5 and wherein said M'O, Al 2 O 3 and SiO 2 constituent of said stoichiometric formula can range to less than ±10% from said stoichiometric formula, said composite containing an amorphous glassy phase in an amount of less than about 5% by volume of said composite, said composite containing no significant reaction product of said filler and said matrix phase.

Claim 33

A composite having a porosity of less than about 5% by volume consisting essentially of polycrystalline inorganic filler ranging in amount from about 5% by volume to about 70% by volume of said composite, said filler being free of oxide and silicon nitride fillers, and a continuous interconnecting polycrystalline alkaline earth aluminosilicate matrix phase ranging in amount from about 95% by volume to about 30% by volume of said composite, said matrix phase being distributed through said composite, the thickness of said matrix phase between said filler ranging from about 0.1 micron to about 10 microns, said alkaline earth aluminosilicate phase being represented by the stoichiometric formula xM'O.yAl 2 O 3 .zSiO 2 where M'=Ca, Mg, Sr and a mixture and/or solid solution thereof, where x is 1, 2, 4 or 6, where y is 1, 2, 5 or 9, where z is 1, 2 or 5 and wherein said M'O, Al 2 O 3 and SiO 2 constituent of said stoichiometric formula can range to less than ±10% from said stoichiometric formula, said composite containing an amorphous glassy phase in an amount of less than about 5% by volume of said composite, said composite containing no significant reaction product of said filler and said matrix phase.

Claim 34

The composite according to claim 29 wherein said ceramic filler phase is comprised of a ceramic carbide selected from the group consisting of boron carbide, hafnium carbide,niobium carbide, silicon carbide, tantalum carbide, titanium carbide, vanadium carbide, zirconium carbide and a mixture thereof.

Claim 35

The composite according to claim 29 wherein said ceramic filler phase is comprised of a ceramic nitride selected from the group consisting of hafnium nitride, niobium nitride, tantalum nitride, titanium nitride, vanadium nitride, zirconium nitride and a mixture thereof.

Claim 36

The composite according to claim 29 wherein said ceramic filler phase is comprised of a ceramic boride selected from the group consisting of HfB 2 , NbB, NbB 2 , TaB, TaB 2 , TiB 2 , VB, VB 2 , ZrB 2 and a mixture thereof.

Claim 37

A composite according to claim 29 wherein said composite is comprised of from about 25% by volume to about 65% by volume of said ceramic filler phase, and from about 35% by volume to about 75% by volume of said continuous matrix phase.

Claim 38

The composite according to claim 29 wherein said infiltrant is SrO.Al 2 O 3 .2SiO 2 wherein each oxidic constituent of said SrO.Al 2 O 3 .2SiO 2 ranges up to ±50% from its stoichiometric composition.

Claim 39

The composite according to claim 29 wherein said ceramic filler phase is comprised of particles.

Claim 40

The composite according to claim 29 wherein said ceramic filler phase is comprised of filaments.

Claim 41

The composite according to claim 29 wherein said ceramic filler phase is comprised of a mixture of particles and filaments.

Claim 42

A composite having a porosity of less than about 10% by volume consisting essentially of polycrystalline inorganic filler ranging in amount from about 5% by volume to about 70% by volume of said composite, said filler being free of oxide filler, and a continuous interconnecting polycrystalline alkaline earth silicate matrix phase ranging in amount from about 95% by volume to about 30% by volume of said composite, said matrix phase being distributed through said composite, the thickness of said matrix phase between said filler ranging from about 0.1 micron to about 10 microns, said alkaline earth silicate phase being selected from the group consisting of CaO.SiO 2 , SrO.SiO 2 and a mixture and/or solid solution thereof wherein said CaO, SrO and SiO 2 constituents of said formulas range less than ±10% from said formulas, said composite containing an amorphous glassy phase in an amount of less than about 5% by volume of said composite, said composite containing no significant reaction product of said filler and said matrix phase.

Claim 43

A composite having a porosity of less than about 10% by volume consisting essentially of polycrystalline inorganic filler ranging in amount from about 5% by volume to about 70% by volume of said composite, said filler being free of oxide filler, and a continuous interconnecting polycrystalline alkaline earth silicate matrix phase ranging in amount from about 95% by volume to about 30% by volume of said composite, said matrix phase being distributed through said composite, the thickness of said matrix phase between said filler ranging from about 0.1 micron to about 10 microns, said alkaline earth silicate phase being selected from the group consisting of CaO.SiO 2 , SrO.SiO 2 and a mixture and/or solid solution thereof wherein said CaO, SrO and SiO 2 constituents of said formulas range less than ±10% from said formulas, said composite containing an amorphous glassy phase in an amount of less than about 5% by volume of said composite, said composite containing no significant reaction product of said filler and said matrix phase.

Claim 44

A composite having a porosity of less than about 10% by volume consisting essentially of polycrystalline inorganic filler ranging in amount from about 5% by volume to about 70% by volume of said composite, said filler being free of oxide filler, and a continuous interconnecting polycrystalline alkaline earth aluminosilicate matrix phase ranging in amount from about 95% by volume to about 30% by volume of said composite, said matrix phase being distributed through said composite, the thickness of said matrix phase between said filler ranging from about 0.1 micron to about 10 microns, said alkaline earth aluminosilicate phase being represented by the stoichiometric formula SrO.Al 2 O 3 .2SiO 2 wherein said SrO, Al 2 O 3 and SiO 2 constituents of said formula range less than ±10% from said formula, said composite containing an amorphous glassy phase in an amount of less than about 5% by volume of said composite, said composite containing no significant reaction product of said filler and said matrix phase.

Claim 45

A composite having a porosity of less than about 10% by volume consisting essentially of polycrystalline inorganic filler ranging in amount from about 5% by volume to about 70% by volume of said composite, said filler being free of oxide filler, and a continuous interconnecting polycrystalline alkaline earth aluminosilicate matrix phase ranging in amount from about 95% by volume to about 30% by volume of said composite, said matrix phase being distributed through said composite, the thickness of said matrix phase between said filler ranging from about 0.1 micron to about 10 microns, said alkaline earth aluminosilicate phase being represented by the stoichiometric formula SrO.Al 2 O 3 .2SiO 2 wherein said SrO, Al 2 O 3 and SiO 2 constituents of said formula range less than ±10% from said formula, said composite containing an amorphous glassy phase in an amount of less than about 5% by volume of said composite, said composite containing no significant reaction product of said filler and said matrix phase.